Thermal safety remains a key hurdle for large-scale sodium-ion battery (SIB) deployment. This investigation quantifies how cycle aging and electrode composition reshape runaway behavior in two commercial cylindrical cells: 18650-1 Ah and 26700-2.85 Ah. An extended-volume accelerating-rate calorimeter operated in Heat–Wait–Seek mode tracked self-heating from ambient to 200 ℃, capturing characteristic temperatures for trigger, acceleration and peak combustion. Aging depressed the first two thresholds by 20–46 ℃ in both formats, compressing the abuse-tolerance window even though final peak temperatures declined by < 10%. Regardless of age, the 26700 maintained markedly higher stability and a 25 ℃ cooler peak than the 18650, underscoring the benefits of a more refractory interphase, flame-retardant electrolyte and ceramic-filled separator. Mechanistic analysis links the faster failure of aged to SEI cracking, metallic sodium plating, additive depletion and oxygen release from the layered-oxide cathode. These results show that SIB safety advantages over lithium-ion chemistry depend on careful materials design and aging-aware thermal management. The findings provide quantitative guidance for pack design and early-warning thresholds in grid-scale SIB storage.

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Experimental Analysis and Safety Assessment of Thermal Runaway Behavior in Sodium-Ion Batteries Under Thermal Abuse

  • Ziqi Wang,
  • Shuquan Wang,
  • Hao Tian,
  • Zhengwei Zhao

摘要

Thermal safety remains a key hurdle for large-scale sodium-ion battery (SIB) deployment. This investigation quantifies how cycle aging and electrode composition reshape runaway behavior in two commercial cylindrical cells: 18650-1 Ah and 26700-2.85 Ah. An extended-volume accelerating-rate calorimeter operated in Heat–Wait–Seek mode tracked self-heating from ambient to 200 ℃, capturing characteristic temperatures for trigger, acceleration and peak combustion. Aging depressed the first two thresholds by 20–46 ℃ in both formats, compressing the abuse-tolerance window even though final peak temperatures declined by < 10%. Regardless of age, the 26700 maintained markedly higher stability and a 25 ℃ cooler peak than the 18650, underscoring the benefits of a more refractory interphase, flame-retardant electrolyte and ceramic-filled separator. Mechanistic analysis links the faster failure of aged to SEI cracking, metallic sodium plating, additive depletion and oxygen release from the layered-oxide cathode. These results show that SIB safety advantages over lithium-ion chemistry depend on careful materials design and aging-aware thermal management. The findings provide quantitative guidance for pack design and early-warning thresholds in grid-scale SIB storage.